Additive manufacturing-driven mold design for castings AITranslate

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DOI：https://doi.org/10.1016/j.addma.2018.04.037

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The advance of additive manufacturing drives the design of molds for castings. In the present study, a type of skeletal mold for castings was proposed, which includes two structures, lattice-shell and rib enforced shell. The shell forms the cavity for a casting and the surrounding ribs or lattices support and enforce the shell. This type of mold structure design results in fast and uniform cooling of a casting, which can improve production efficiency and reduce the deformation and residual stress of a casting. In addition, it provides more space and flexibility to adjust the cooling conditions of interested locations of a casting. The thickness of the shell can be varied according to the local geometries of a casting. The support is designed based on the hydrostatic pressure before solidification and the weight after solidification. An air pocket (hollow structure) in the shell was designed for the riser to postpone its solidification and then facilitate shrinkage feeding. The experimental results revealed that the new design of sand molds saved at least 60% sand and shortened the shakeout time by at least 20%. Local hollow structure prolonged its solidification process by approximately 15%. Graphical abstract Download : Download high-res image (170KB) Download : Download full-size image